Barrier verification and testing

We will discuss:

When a barrier is lost, the importance of

responding immediately to maintain Integrity.

• Leaks in intervention PCE cannot be repaired

with tools in the well unless it is possible to
close and test two independent barriers.
• PCE BOPs and stuffing boxes must all be
capable of being closed remotely hydraulically
operated, not manually.
• Risk assessments should be used to consider
all potential issues and cover any mitigating
actions that may be required.
 Well barriers
• General Well barriers are envelopes
of one or several dependent
WBEs preventing fluids or gases
from flowing unintentionally from
the formation, into another
formation, or to the surface. The
well barrier(s) shall be defined prior
to commencement of an activity or
operation by a description of the
required WBEs to be in place and
specific acceptance criteria.
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 Well barriers
• Primary well barrier
elements in its normal working
stage, which for some situations
is the fluid column or a
mechanical well barrier that
provides closure of the well
barrier envelope,
• Secondary well barrier
elements in its ultimate stage,
which in most cases describes a
situation where the shear/seal
rams are closed.
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Well barriers

• General Well barrier acceptance

criteria are technical and
operational requirements that need
to be fulfilled in order to qualify the
well barrier or WBE for its intended
use

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 Well barriers

Function and number of well barriers

• The function of the well barrier elements

(WBE) shall be clearly defined. There
shall be two barriers in place during all
well activities and operations, including
suspended or abandoned wells, where
a pressure differential exists that may
cause uncontrolled cross-flow in the
wellbore between formation zones.

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 Well barriers
The well barriers shall be designed,
selected, and/or constructed such that
• It can withstand the maximum
anticipated differential pressure it may
become exposed to,
• It can be leak tested and function
tested or verified by other methods,
• No single failure of well barrier or
WBE leads to uncontrolled outflow
from the well to the external
environment

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 Well barriers
The well barriers shall be designed,
selected and/or constructed such that,
• Re-establishment of a lost well barrier or
another alternative well barrier can be
done
• ‘It can operate competently and withstand
the environment for which it may be
exposed to overtime
• Its physical location and integrity status of
the well barrier is known at all times when
such monitoring is possible.

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 H2S leak through stuffing box
Well barriers
The primary and secondary well barriers
shall to the extent possible be independent
of each other without common WBEs. If
common WBEs exist, a risk analysis shall be
performed, and risk reducing/mitigation
measures applied to reduce the risk as low
as reasonably practicable.

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Well barriers
Less leaking paths
One of the well barriers should have WBE(s)
that can
• Shear any tool that penetrates PCE
and seals the wellbore after having
sheared the tool. If this is not achievable,
well barrier descriptions for operational
situations which do not require shearing
of tools shall be identified,
• Seal the wellbore with any size tool that
penetrates the PCE. If this is not
achievable, well barrier descriptions for
operational situations which require
shearing of tools shall be identified.
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 Well barriers
Initial verification of the well barrier When
the well barrier has been constructed, its
integrity and function shall be verified by
means of
a. Leak testing by application of differential
pressure,
b. Functioned testing of WBEs that require
activation,
c. Verification by other specified methods.

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 Well barriers
Leak testing of well barriers or WBEs
shall be performed
a) Before it can become exposed to
pressure differentials,
b) After replacement of pressure confining
components of the well barrier,
c) When there is a suspicion of a leak,
d) When an element will become exposed
to different pressure/load than it
originally was designed for,
e) Routinely,.
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 Well barriers
Pressure direction
The pressure should be applied in the flow
direction. If this is impractical, the pressure
can be applied against the flow direction,
providing that the WBE is constructed to seal
in both flow directions or by reducing the
pressure on the downstream side of the well
barrier to the lowest practical pressure (inflow
test).

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 Well barriers
• Leak test pressure values and duration A low-
pressure leak test to 200 psi – 300 psi (15 bar
20 bar Norway) 1,5 MPa, 2 bar 2 MPa for 5 min
should be performed prior to high-pressure
leak testing.
• The high-pressure leak test value shall be
equal to or exceed the maximum anticipated
differential pressure that the WBE will
become exposed to.
• Static leak test pressure shall be observed and
recorded for a minimum of 10 min.
• The above test values shall not exceed the
rated WP of any WBE.
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 Well barriers
Acceptable leak rates The acceptable leak
rate shall be zero unless specified otherwise.
For situations where the leak rate cannot be
monitored or measured, the criteria for
maximum allowable pressure fluctuation shall
be established.

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 Well barriers
Function testing of well barriers A function
test of the WBE(s) shall be performed
a. After installation,
b. After having been subjected to abnormal
loads,
c. After repairs,
d. Routinely

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There are very few situations when fluid can
be used as a barrier during WIPC operations.
When it is used as a barrier, it has to be:
• Equal to kill weight,
• Be monitorable, and the level must be
maintained
Documentation of leak and function testing of
well barriers All well integrity tests shall be
documented and accepted by an authorized
person. This authorized person can be the
driller, tool-pusher, drilling and well
intervention supervisor or the equipment and
service provider's representative.
The chart and the test documentation should
contain
a) Type of test,
b) Test pressure,
c) Test fluid,
d) System or components tested,
e) Estimated volume of system pressurized,
f) Volume pumped and bled off
Well barrier monitoring All parameters relevant
for preventing uncontrolled flow from the well
shall be monitored. Methods and frequency for
verifying the condition of the well
barrier/WBEs shall be defined and
documented. All instrumentation used for
required monitoring of parameters shall be
frequently checked and calibrated.
 EQUIPMENT INSPECTIONS
Visually inspect all equipment as follows:
• Look closely at the equipment from all
angles
• Use a magnifying device to look for
potential signs of damage; consult a
supervisor for a second opinion.
• Use your hands to feel for unusual
changes, such as corrosion, cracking and
gauges.
• Any pressure control equipment involved in
misuse, abuse, or subjected to pressure
beyond its rating must undergo additional
Inspection and Pressure Test
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 Equipment Visual Inspection
Visually inspect off all equipment before any
well operation take place is crucial. Equipment
and personnel must be inspected and tested
before any well operation take place. The
minimum inspections are :
• All Seals inspected and replaced when
needed
• All Equipment rigged up must be correct
installed and marked with the relevant
manufacture plate and certificate on site.
• All Equipment must also be function tested
and pressure test before any well intervention
take place.

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PCE verification
Prior to starting operations, pressure
control equipment is verified
a) Design verification
b) Function test BOP once a week
c) Pressure testing
d) Initial test performed prior to
deployment
e) Subsequent test during operation

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PCE verification
• Ensure equipment is suitable for
intended operations
• Design standard, pressure,
temperature, fluids
• Ensure equipment is certified for
these conditions
• Re-certification is required at a
fixed interval
• Certification by independent body

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PCE verification
Certification specifies, e.g.
• Manufacturing and testing
standard (API, ISO )
• Unique serial number
• Type of service suitability (CO2,
H2S)
• Max working pressure
• Temperature rating

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 Verification Check – Example
• Hydraulic hoses and connectors clean,
including connector seals
• Stuffing box and/or grease injection head
clean, serviced, and operable
• Lubricator quick unions clean, O-rings
replaced where necessary, bleed valves
operable and clean, not corroded
• BOPs clean, operable, serviced
• Wellhead adapter appropriate, clean, and
provided with ring gasket
• All equipment provided with up to date
pressure test and material tests
• Sufficient stock of grease on location

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 Verification Check – Example
Rams
• Inner seal for wire or as blind: molding to be in good shape,
not loose or worn;
• Inner seal screws tight and not broken;
• Outer seal smooth and flexible
Critical Components
• Connections
• Ring grooves and gaskets
• Hydraulics
• Actuator O-rings and seals
• BOP
• Ram seal and cutting inserts
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Equipment Verification
Function testing (weekly API)
• After rig up, function testing is
performed.
• Checks all items work as intended.
• Function testing pressure control types
of equipment is part of the regular
(BOP) test procedures.

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 Equipment Verification
Inflow testing
• When, testing in direction of flow is not possible
• Lower master valve, packers, WL plugs
• Close barrier and bleed down the section
downstream
• Use upstream well pressure as test pressure
• Bled down section is closed against a tested
barrier
• Monitor bled down section for any pressure
increase

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Equipment Verification
Alternative testing from above
• When testing in direction of flow and inflow
test is not possible
• Lower master valve, packers, WL plugs
• The pressure test to be applied by pressure
from above

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 Questions ?
Before installing PCE on the Xmas
Tree What needs to be done?

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Gauge range
Pressure measurements
should be made not less than
25% nor more than 75 % of
the full span of the gauge.

Let's say we read a 6100 psi SIWHP.

Select the correct gauge range
Gauge Range
Pressure measurements should be made not less than 25% nor
more than 75 % of the full span of the gauge.
n
Gauge selection
• The pressure gauge selected should have a full scale
pressure such that the operating pressure occurs in the
middle half (25% to 75%) of the scale (12 o'clock position is
best).
• The full scale pressure of the gauge selected should be
approximately two times the intended operating pressure.
• Valid calibration
• This will give the operator a visual indication of normal, ideal
operating conditions.
• This means a "green light" condition and everything is
operating the way it should be. If however, the "visual" of
the pointer is way below or way above this 12 o'clock
position, then this will give the red light warning indication

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Gauge selection
Pressure gauges need the correct
• Range ideally 12 o'clock is a fine
position of the shut in wellhead
pressure meaning if the well pressure is
5000 psi a 10000 psi full range can be
used
• Temperature range and rating correctly
selected according to maximum well
temperature and pressure
• Calibration updated,valid and signed
• Correct sensitivity and resolution
• A gauge must never be pressured up
above its maximum rating. That will
destroy the gauge.
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